2D/3D LASER PROFILER – HIGH-RESOLUTION INLINE MEASUREMENT
Laser profilers are laser displacement sensors that collect height data across a laser line rather than a single point, making it possible to complete height difference measurements across wide areas without the need for motion or multiple sensors. These sensors can be configured to measure height, height difference, width, depth, level of defect, character recognition and many more. Using a laser profiler allows you to perform all of the above-mentioned measurements without touching the target. The laser profiler’s high-speed acquisition of high-resolution profiles enables reliable quality and process control solutions for a variety of applications and industries. By installing laser profilers into a production line, manufacturers can improve throughput by performing height difference, warpage, and other 2D/3D measurements without stopping the product.
2D/3D LASER PROFILER – HIGH-RESOLUTION INLINE MEASUREMENT
Laser profilers are laser displacement sensors that collect height data across a laser line rather than a single point, making it possible to complete height difference measurements across wide areas without the need for motion or multiple sensors. These sensors can be configured to measure height, height difference, width, depth, level of defect, character recognition and many more. Using a laser profiler allows you to perform all of the above-mentioned measurements without touching the target. The laser profiler’s high-speed acquisition of high-resolution profiles enables reliable quality and process control solutions for a variety of applications and industries. By installing laser profilers into a production line, manufacturers can improve throughput by performing height difference, warpage, and other 2D/3D measurements without stopping the product.
Advantages of using laser profiler system:
Contact-type measuring:
Disadvantages of contact-type measuring:
- Can’t be used on scratch-sensitive or delicate products such as printed circuit boards.
- It can be difficult to measure complex items or shapes with a large area.
- Can’t be performed on high-speed production line.
- Can’t perform measurements of soft products without changing the shape with pressure from the contact.
- While automation is important in today’s industry, measuring’s performed by humans cannot be automated.
- Using contact-type measuring systems always has a big risk of human error.
Advantages of laser profilers:
- Can perform contactless measurements of these delicate targets during production, without damaging them.
- Multiple sensor heads can be combined to scan complex shapes.
- Laser profilers can perform measurements on running conveyor, without stopping the parts for inspection.
- Unlike contact-based measurement devices, laser profilers can accurately measure the profiles of rubber products, food items, and other such soft objects or targets that could be damaged through contact.
- Laser profiler systems provide 100% inspections at speeds and quality far existing any human capability
- Automating profile measurement also removes the dependence on operators, eliminating the risk of human error or variation in measurement methods, thus improving reliability while reducing inspection time.
Camera vision systems:
Disadvantages of camera inspection systems:
- Camera-based inspection can be difficult for certain applications due to lighting conditions. That’s why conventional area cameras and line scan cameras need lighting fixtures to be installed.
- Lack of color contrast makes it difficult to configure inspection program
- The scope is limited to 2D measurements, cameras cannot measure height, and even aiming from an angle does not enable reliable inspection due to the inability to fully focus an image from the front to the back of a target, so height inspection must be completed separately.
Advantages of laser profilers:
- Can perform contactless measurements of these delicate targets during production, without damaging them.
- Multiple sensor heads can be combined to scan complex shapes.
- Laser profilers can perform measurements on running conveyor, without stopping the parts for inspection.
- Unlike contact-based measurement devices, laser profilers can accurately measure the profiles of rubber products, food items, and other such soft objects or targets that could be damaged through contact.
- Laser profiler systems provide 100% inspections at speeds and quality far existing any human capability
- Automating profile measurement also removes the dependence on operators, eliminating the risk of human error or variation in measurement methods, thus improving reliability while reducing inspection time.
Advantages of laser profiler inspection systems:
- Laser profilers can complete inspection and defect detection of any material without external lighting.
- With only a sensor head installed, a laser profiler can be used to inspect height and other 3D profile data by capturing the object’s shape from above.
- Laser profilers can also achieve reliable inline profile measurements without being affected by color differences, patterns, and other characteristics of the target object.
Industry applications:
Smartphone assembly
Targets with multiple materials can be captured in a single profile, allowing measurements to be made between glass and metal surfaces. Laser profilers we use for our system are equipped to handle reflectances ten times higher than conventional products.
Tire shape / DOT code inspection
With upstanding X-axis and Z-axis precision, it’s possible to hold tighter tolerances over a wider inspection area. This significantly expands the types of applications that can use 3D measurement.
Post-welding inspection
Bead profile measurement makes it possible to inspect work for melting, undercutting and so forth after welding. When the measurement device is run behind the welding torch, it performs in-line automatic inspections of all items and determines the quality of the weld using the profile, eliminating misdetections caused by color abnormalities.
PCB Inspection
Inspect the height, position, presence and shape of a mounted part. By using parallel light, the sensor captures target shape accurately, right down to the fine details. The adjustment function can handle misaligned and tilted targets, so accurate inspection is possible without stopping the target.
Camera module assembly check
For camera modules with multiple functions, it’s necessary to confirm the relative position of various elements. Performing high precision assembly inspection is possible with a single sensor using 3D data.
Sheet thickness, width, and edge profile
Measures edge position, width and height difference for rubber sheets on rollers to detect defects. 2-head measurement allows for simultaneous left and right edge detection.
Character recognition (OCR) on cast surfaces
Characters machined on cast surfaces can be identified. Detection using height data allows for stable reading, even for characters on rough metal surfaces.
Lumber grading
Large targets often exceed the measuring range of conventional devices. With this lineup of long-range and high-precision measuring devices, full-circumference measurement becomes possible even for timber. Three-dimensional inspection makes it possible to perform inline inspections of outer diameter, roundness, warpage and other deformations.
Door panel flush and gap
Measure door panel flush and gap without touching the car. The sensor settings don’t need to be adjusted for variations in body color or size, making it easy to automate external appearance inspection.
Sealant height, width, and volume
Improve quality control by confirming sealant bead height, width, and area, rather than checking for presence alone. Even sudden, small abnormalities can be detected.